Solar cell having an integral monolithically grown bypass diode

ABSTRACT

The present invention is directed to systems and methods for protecting a solar cell. The solar cell includes first solar cell portion. The first solar cell portion includes at least one junction and at least one solar cell contact on a backside of the first solar cell portion. At least one bypass diode portion is epitaxially grown on the first solar cell portion. The bypass diode has at least one contact. An interconnect couples the solar cell contact to the diode contact.

The present application is a divisional application of U.S. patentapplication Ser. No. 10/336,247, filed on Jan. 3, 2003, now U.S. Pat.No. 7,115,811, which is a continuation application of U.S. patentapplication Ser. No. 09/934,221, filed on Aug. 21, 2001, now U.S. Pat.No. 6,600,100, issued Jul. 29, 2003, which is a divisional applicationof U.S. patent application Ser. No. 09/314,597, filed on May 19, 1999,now U.S. Patent No. 6,278,054, issued Aug. 21, 2001, which claimspriority from U.S. provisional patent application Serial No. 60/087,206,filed on May 28, 1998. The contents of the above-referenced applicationsare hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to solar cells. In particular, the presentinvention relates to methods and apparatuses for providing a solar cellwith an integral diode.

2. Description of the Related Art

Photovoltaic cells, commonly called solar cells, are well-known deviceswhich convert solar energy into electrical energy. Solar cells have longbeen used to generate electrical power in both terrestrial and spaceapplications. Solar cells offer several advantages over moreconventional power sources. For example, solar cells offer a cleanmethod for generating electricity. Furthermore, solar cells do not haveto be replenished with fossil fuels. Instead, solar cells are powered bythe virtually limitless energy of the sun. However, the use of solarcells has been limited because solar cells are a relatively expensivemethod of generating electricity. Nonetheless, the solar cell is anattractive device for generating energy in space, where low-costconventional power sources are unavailable.

Solar cells are typically assembled into arrays of solar cells connectedtogether in series, or in parallel, or in a series-parallel combination.The desired output voltage and current, at least in part, determine thenumber of cells in an array, as well as the array topology.

As is well known in the art, when all cells in an array are illuminated,each cell will be forward biased. However, if one or more of the cellsis shadowed (i.e., not illuminated), by a satellite antenna or the like,the shadowed cell or cells may become reversed biased because of thevoltage generated by the unshadowed cells. Reverse biasing of a cell cancause permanent degradation in cell performance or even complete cellfailure. To guard against such damage, it is customary to provideprotective bypass diodes. One bypass diode may be connected acrossseveral cells, or for enhanced reliability, each cell may have its ownbypass diode. Multijunction solar cells are particularly susceptible todamage when subjected to a reverse bias condition. Thus, multijunctioncells in particular benefit from having one bypass diode per cell.Conventionally, a bypass diode is connected in an anti-parallelconfiguration, with the anode and the cathode of the bypass dioderespectively connected to the cathode and the anode of the solar cell,so that the bypass diode will be reversed biased when the cells areilluminated. When a cell is shadowed, current through the shadowed cellbecomes limited and the shadowed cell becomes reverse biased. The bypassdiode connected across the shadowed cell in turn becomes forward biased.Most of the current will flow through the bypass diode rather thanthrough the shadowed cell, thereby allowing current to continue flowingthrough the array. In addition, the bypass diode limits the reverse biasvoltage across the shadowed cell, thereby protecting the shadowed cell.

Several different conventional methods have been used to provide solarcells with bypass diode protection. Each conventional method has itsdrawbacks. For example, in an attempt to provide increased bypassprotection, one method involves locating a bypass diode between adjacentcells, with the anode of the bypass diode connected to one cell and thecathode of the diode connected to an adjoining cell. However, thistechnique requires that the cells be assembled into an array before thebypass diode protection can be added. This assembly method is difficultand inefficient. Furthermore, this technique requires the bypass diodesto be added by the array assembler, rather than the cell manufacturer.In addition, this technique requires the cells to be spaced far enoughapart so as to accommodate the bypass diode. This spacing results in thearray having a lower packing factor, and thus, the array is lessefficient on an area basis.

Another conventional technique for providing a bypass diode for eachcell requires that a recess be formed on the back of the cell in which abypass diode is placed. Each cell is provided with a first polaritycontact on a front surface of the cell and a second polarity contact isprovided on a back surface of each cell. An “S” shaped interconnect mustthen be welded from a back surface contact of a first cell to a frontsurface contact of an adjoining cell. Thus, this techniquedisadvantageously requires the cells to be spaced far enough apart toaccommodate the interconnect which must pass between the adjoiningcells. Additional disadvantages of this method include the possibilityof microcracks generated during formation of the recess. In addition,this technique requires a thick bondline of adhesive, thereby addingstress-risers, increasing stresses generated during temperature cycling.Furthermore, the present conventional techniques requires the connectionof the interconnect to the adjoining cell to be performed by the arrayassembler as opposed to the cell manufacturer.

SUMMARY OF THE INVENTION

One embodiment of the present invention advantageously provides methodsand systems for efficiently providing an integral bypass diode on asolar cell. In one embodiment, the solar cell is a multijunction cell.The bypass diode is monolithically grown over at least a portion of thesolar cell. In another embodiment, the solar cell is formed from atleast group III, IV, or V materials. In still another embodiment, thediode includes at least an N-type GaAs layer and a P-type GasAs layer.In yet another embodiment, the diode is formed using lower bandgapmaterials, such as germanium or InGaAs.

In one embodiment, the solar cell includes a germanium Ge substrate. TheGe substrate may further include a photoactive junction. In yet anotherembodiment, the substrate is formed from at least one of the followingmaterials: semiconductors, such as GaAs, Si, or InP, and insulators,such as sapphire. In one embodiment, the substrate is a single crystal.

In yet another embodiment, a C-clamp conductor interconnects at leastone solar cell contact to at least one bypass diode contact. In anotherembodiment, an integrally metallized layer is used to interconnect atleast one solar cell contact to at least one bypass diode contact. Instill another embodiment, the integrally metallized layer is depositedover an insulating layer to prevent the integrally metallized layer fromshorting to one or more other layers.

In one embodiment, a cap layer interconnects a first diode polarity withthe solar cell. In yet another embodiment, the bypass diode isepitaxially grown on a solar cell having one or more junctions. In stillanother embodiment, the solar cell may be formed from at least one ormore of the following materials: GaAs, InP, GaInP₂, and AIGaAs. Inanother embodiment, other III-V compounds are used to form at least aportion of the solar cell.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects, advantages, and novel features of the inventionwill become apparent upon reading the following detailed description andupon reference to accompanying drawings in which:

FIG. 1 illustrates a first processing step used to construct oneembodiment of the present invention;

FIG. 2 illustrates a second processing step used to construct oneembodiment of the present invention;

FIG. 3 illustrates a third processing step used to construct oneembodiment of the present invention;

FIG. 4 illustrates a fourth processing step used to construct oneembodiment of the present invention;

FIG. 5 illustrates a fifth processing step used to construct oneembodiment of the present invention;

FIG. 6 illustrates a sixth processing step used to construct oneembodiment of the present invention;

FIG. 7 illustrates a seventh processing step used to construct oneembodiment of the present invention;

FIG. 8 illustrates an eighth processing step used to construct oneembodiment of the present invention;

FIG. 9 illustrates a ninth processing step used to construct oneembodiment of the present invention;

FIG. 10 illustrates a tenth processing step used to construct oneembodiment of the present invention;

FIG. 11 illustrates one embodiment of the present invention, including adiscrete interconnect;

FIG. 12 illustrates one embodiment of the present invention, includingan integral interconnect;

FIG. 13A illustrates a perspective view of one embodiment of the presentinvention;

FIG. 13B illustrates in greater detail the bypass diode illustrated inFIG. 13A.

FIG. 14A illustrates one embodiment of the present invention with aburied bypass diode;

FIG. 14B illustrates the embodiment of FIG. 14A after further processingacts are performed;

FIG. 15A illustrates a first method of interconnecting solar cells; and

FIG. 15B illustrates a second method of interconnecting solar cells.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to a solar cell with at least one integralbypass diode. The solar cell may be a single junction or multijunctioncell. As discussed below, in one embodiment, a bypass diode isepitaxially grown on a multijunction solar cell. The solar cell/bypassdiode device may be interconnected with other solar cells to form seriesand/or parallel strings of solar cells. The strings may be furtherconnected to form a reliable and robust solar cell array. The solar cellarray may be mounted to a space vehicle, thereby providing power to thespace vehicle.

FIG. 1 shows a sequence of III-V layers 106-122 which are grownsequentially on a Ge substrate 102 in one embodiment of the presentinvention to form a multijunction solar cell 100. The Ge substrate 102may further include a photoactive junction. In one embodiment, thelayers are epitaxially grown, meaning that they replicate the singlecrystalline structure of material. The growth parameters (depositiontemperature, growth rate, compound alloy composition, and impuritydopant concentrations) are preferably optimized to provide layers withthe desired electrical qualities and thickness, to thereby obtain therequired overall cell performance. The epitaxial techniques which may beused to grow the cell layers include, by way of example, MOCVD(metal-organic chemical vapor deposition) epitaxy, sometimes calledOMVPE (organic-metallic vapor phase epitaxy), MBE (molecular beamexpitaxy), and MOMBE (metal-organic molecular beam epitaxy).

In the illustrated embodiment, an N doped GaAs base layer 106 is grownover and overlays at least a portion of the substrate 102. At theinterface between layer 102 and layer 106 a photoactive junction isformed. In one embodiment, the photoactive junction is an N+GaAs/N+Geheterodiode. In another embodiment, if an N/P configuration is to begrown, a P-type Ge substrate 102 is used, and diffusion of As from thelayer 106 forms an N/P junction in the substrate 102.

As illustrated in FIG. 1, a highly P doped GaAs emitter layer 108 isgrown over at least a portion of the GaAs base layer 106. The base layer106 and the emitter layer 108 together form a lower cell stage. A highlyP doped AlGaAs window layer 110 overlays the emitter layer 108. A tunneldiode, including very highly doped P and N layers 112, 114 is grown overthe window layer 110. A second, or upper cell stage, including an Ndoped base layer 116 and a highly P doped emitter layer 118, is formedover the tunnel diode.

In one embodiment, the last two layers grown for the solar cell arerespectively a highly P doped AlGaAs window 120, which is a thin,transparent layer that passivates (reduces carrier recombination) thesurface of the emitter layer 118 of the top cell (GaInP₂), and a GaAscap-layer 122 onto which the front surface ohmic contacts are deposited.In one embodiment, the contacts are in grid-finger form, to balance lowelectrical resistance and high optical transparency. However, othercontact patterns may be used as well. In the present embodiment, asdescribed below, the integral bypass diode is included in themonolithically-grown cell structure by the growth of several additionallayers. The cap layer 122 is selectively removed between the gridlines,and anti-reflective coatings are deposited over the top window layer120.

It will be understood by one of ordinary skill in the art, that thethree cell, three-junction, solar cell 100, illustrated in FIG. 1, isonly one of many possible cell embodiments which can be used with thepresent invention. In another embodiment, a complementary structure,with the polarities of one or more layers switched (i.e., N doped layersare, instead, P doped, and P doped layers are, instead, N doped), may beused. For example, the cell and diode configurations illustrated in thefigures and discussed below, can be changed from P/N to N/P. Also, thedoping concentrations or layer thicknesses may be varied. Furthermore,in other embodiments, the solar cell 100 may include four or morephotovoltaic cells, or only one or two cells. Similarly, the solar cellmay alternatively include only one junction or two or more junctions. Byway of example, in one embodiment, the cell 100 may include fourjunctions.

Furthermore, the solar cell 100 may include cells made from othermaterials, such as AlGaAs or InP. In other embodiments, the substrate102 may be formed using a variety of different materials. For example,the solar cell 100 may use other semiconductors, such as GaAs, Si, orInP for the substrate, rather than the Ge substrate 102 illustrated inFIG. 1. Alternatively, insulating substrates, such as sapphire, may beused. In one embodiment, the substrate 102 is a single crystal. If thesolar cell 100 is intended for space use, such as on a space vehicle orsatellite, then the cell materials are preferably space-qualified forthe appropriate space environment. For example, the solar cell 100 andbypass diode may be space qualified to operate in an AMO radiationenvironment.

One method of fabricating the bypass diode will now be described. Asillustrated in FIG. 2, the bypass diode 212 is included in the solarcell structure using five additional grown layers 202, 204, 206, 208,216.

As previously described, in one embodiment, the layers 106-122,comprising the photovoltaic portions 124 of the multijunction solarcell, 100, are first grown, and the growth cycle is continued to growthe additional layers 202-210. From the P-type GaAs cap layer 122 usedfor front grid contacts, the additional layers in order are:

-   -   the highly doped N-GaAs connecting layer 202 used to reduce        contact resistance to the N-GaAs diode layer 206 and to the        highly doped GaAs cap layer 122.    -   the stop-etch layer 204 (highly N-doped AlGaAs or GaImP) used to        allow controlled etch-removal of the three diode layers 206-210.    -   the N doped GaAs layer 206, comprising the negatively doped part        of the bypass diode 212.    -   the P doped GaAs layer 208, comprising the positively doped part        of the of the bypass diode 212.    -   the highly doped P-GaAs cap layer 216, used to provide good        metallic contact to the P-layer 208 of the diode 212.

However, as will be appreciated by one of ordinary skill in the art,other embodiments of the present invention may utilize a differentnumber of layers, formed from different types of materials, and havingdifferent dopants than the embodiment described above. For example, theuse of the complementary structure, that is, N/P rather than P/N, cansimilarly consist of N/P multijunction solar cells, and an N/P bypassdiode. Also, the diode 212 may be formed using lower bandgap materials,such as germanium or InGaAs. In another embodiment, the layer 202 may beomitted, leaving the layer 204 to provide stop-etching and electricalconduction.

A description of one method of processing a wafer to form one embodimentof the invention will now be described. In the present embodiment, theprocess steps are used to grow, define by mesa etch, and interconnectone embodiment of the bypass diode 212 into the cascade (multijunction)cell 100.

First, the photoactive solar cell layers and the diode layersillustrated in FIG. 2 are epitaxially grown using conventional MOCVDand/or MBE technologies. As illustrated in FIG. 3, the front surface ofthe grown layer sequence is protected with a photoresist layer 302,which is exposed through a photomask (not shown) patterned to leave thediode layers covered with resist. As illustrated in FIG. 4, the diodecap layer 210 and the N and P diode layers 206, 208 are etched down tothe stop-etch layer 204. The etching may be performed using citric acidheated to 45° C. As illustrated in FIG. 5, the stop etch layer 204 isremoved where the photoresist layer 302 does not mask, and appropriateportions of the N doped GaAs connecting layer 202 is exposed. If thestop etch layer 204 is AlGaAs, then in one embodiment, the etchant maybe BHF (buffered hydrofloric) acid. If the stop etch layer 204 is GaInP,then in another embodiment, the etchant may be HCI. As illustrated inFIG. 6, the photoresist layer 302 is removed using acetone.Microstripping techniques may be used to remove any residual photoresistleft remaining after the acetone removal process.

Once the photoresist layer 312 is removed, the front contact fabricationprocess, including corresponding photoresist coating, baking, exposing,developing, metal evaporation, and lift off operations, can take place.Another photoresist layer (not shown) is coated over the whole surface.The photoresist layer is then baked and exposed with a photomask whichleaves opened areas where contacts are to be deposited to the frontsurface gridlines and pads, to a small region of the exposed N dopedGaAs layer 202, and to the diode cap layer 216. Metals, predominantlyincluding Ag, are evaporated into the exposed areas and over theremaining photoresist layer. In addition to the two contact areas 702,704 illustrated in FIG. 7, the photoresist also provides open slots inthe photoresist, to provide guidlines, and bars/pad contacts to thecell. Next, a lift-off process is performed The solar cell slice 100 isimmersed in acetone, causing the photoresist to swell, and therebybreaks the metal film everywhere except on the regions designated toretain contacts, including contacts 702, 704.

As illustrated in FIG. 8, metals, predominantly including Ag, areevaporated over the back surface of the Ge substrate 102 to form a backmetal contact 802. The contacts 702, 704, 802 are then heat-treated orsintered. Using the front contact metals 702, 704 as etch-masks, theGaAs cap layer 122 is etched off the major part of the exposed frontsurface, as illustrated in FIG. 9. The cap layer 122 remains under themetallized areas, forming part of a low resistance contact mechanism.

As illustrated in FIG. 10, the diode pad metal contacts 702, 704, andthe small contacts shown around the diode 212 are protected with aresist mask, and on the rest of the surface, an anti-reflecting layer1002 is deposited. As illustrated in FIG. 11, the top, P-side, diodecontact 702 is connected to the back cell (N-grid) contact 802 bybonding a thin interconnect 1102. Thus, in one embodiment, theelectrical connection between the P-layer 208 of the P/N GaAs diode 212and the backside of the N doped Ge substrate 102 is formed by a C-clamp1102, which is bonded to both the front diode contact 702 and the rearGe contact 802. Thus, the bypass diode 212 is connected across both ofthe photovoltaic cells. In other embodiments, the bypass diode may beused to bypass one or more photovoltaic cells. Thus, one embodiment ofthe present invention can be used to bypass all the cells in a solarcell structure 100, or less than all the cells in the solar cellstructure 100.

A variety of other interconnect techniques may be used to connect thesolar cell to the bypass diode. The final choice may depend on theadditional complexity and the effect on cell yields and costs whichresults from the use of these alternative approaches. By way of example,descriptions of several others follow.

As illustrated in FIG. 12, in one embodiment, a short contact betweenthe diode top contact and a metallized area on a small trough etcheddown through the cascade cell layers 1206-1218 to expose the Gesubstrate 1204 may be used, rather than a C-clamp. The trough may removeless than 1% of the active cell area, and may be located close to thetop contact of the bypass diode. As in the previous embodiment, theembodiment illustrated in FIG. 12 includes a front metal contact 1224, arear metal contact 1202, and an anti-reflective coasting 1226. Severaldifferent contact configurations may be used. By way of example:

a) In one embodiment (not shown), a short discrete metal interconnect isbonded to the diode contact at one end, and is bonded directly to the Gesurface exposed in the trough. Preferably, the interconnect isgold-plated. A variety of techniques may be used to make the bond. Inone embodiment, the bond is made using eutectic Au—Ge soldering.

b) If (a), direct bonding to the Ge surface is difficult or undesirable,then, in another embodiment, an additional step may be added to thenormal cell processing. The front surface is masked at substantially allregions except where the Ge contact area is needed using dry film orliquid photoresist. Then, when the front metal contacts are depositedthrough another photoresist mask to form the grid, ohmic and diodecontacts, the edges of the trough may be protected with resist by usingan opened area just inside the etched area. The metal for contacting theN—Ge may be deposited in the same or a similar deposition sequence aswhen the front contacts to the cascade cell 100 and the diode contacts702, 704 are formed. In the present case, TiAuAg or equivalent contactsmay serve for the exposed areas on the front surface. A short discretemetal interconnect is bonded to the diode P-contact and the contact tothe N—Ge.

c) As illustrated in FIG. 12, in a fully monolithic structure, a troughor recess is etched to the Ge interface 1204 through the diode and celllayers 1206-1218. Thus, the wall or walls of the trough are formed bythe cell layers. A mask is then used to expose the edges of the trough,and an insulating layer 1220 is deposited on the layer edges and on thearea between the diode cap layer 1218 and the trough. Another mask,which can be included in the main front contact mask, is used to depositmetal 1222, which connects the front contact of the diode to the troughexposing the Ge substrate 1204. In another embodiment, no diode contactsare necessary for the substrate-to-diode interconnect 1222.

FIG. 13A illustrates a perspective view of one embodiment of the solarcell 100, including the bypass diode circuit 212. The front surface ofthe solar cell 100 includes grid lines 1302 interconnected by an ohmicbar 1306. The bar 1306 is shaped to provide an area or recess where thediode 212 is formed. In one embodiment, the diode 212 is interconnectedto the back contact 802 of the solar cell 100 using the C-clampconnector 1102 illustrated in FIG. 11. FIG. 13B illustrates in greaterdetail the bypass diode 212 illustrated in FIG. 13A. In one embodiment,the sides of the diode 212 are interdigitated with the ohmic bar 1306.Thus, the distance between the diode 212 and the bar 1306 is reduced.and more of the bar 1306 is in proximity with the diode 212.

As illustrated in FIG. 13A, in one embodiment, three tabs 1304 aremounted on the solar cell 100 for interconnection to an adjoiningassembly. The tabs 1304 may include a U-shaped stress relief section,also called a Z-tab. A first side of each of the tabs 1304 is connectedto an anode of the cell 100. The solar cell 100 may be interconnected toa second solar cell by connecting a second side of the tabs 1304 to acathode of the second solar cell. In one embodiment, the tabs are formedfrom silver, silver Invar, or silver-clad molybdenum materials.

A coverglass (not shown) may be used to protect the solar cell/bypassdiode device. For space applications, the coverglass may be composed ofceria-doped borosilicate coverglass. In one embodiment, the coverglassmay have a thickness around 50 μm to 200 μm. The ceria-doped coverglassprovides radiation resistant shielding for charged and unchargedparticles. In one embodiment, the coverglass will remain substantiallytransparent when exposed to an AMO space radiation environment spectrum(the spectrum found at Earth's orbit around the sun, outside of Earth'satmosphere). A major advantage of one embodiment of the integral bypassdiode is that the diode does not extend above the front surface of thesolar cell 100, and therefore does not require the use of a notched orslotted coverglass to accommodate the integral diode. However, inanother embodiment, the integral diode may extend above the front or topsurface of the solar cell 100. One skilled in the art will understandthat other suitable coverglass materials and dimensions can be used aswell.

FIG. 14A illustrates still another embodiment of the present invention.The illustrated solar cell 1400 includes a novel buried protectivebypass diode 1410. As with the bypass diode 212, the protective bypassdiode 1410 is used to protect the solar cell from reverse biasconditions which can result from the shadowing of the cell.

The exemplary grown layer sequence illustrated in FIG. 14A is similar tothat of FIG. 1A. Two additional buried layers 1406, 1408 are providedfor polarity matching with the Ge+ emitter 1404. The solar cell 1400includes a Ge substrate 1402 over which the Ge emitter layer 1404 isgrown. Isolated diode layers 1412-1420 form a portion of the bypassdiode function. Layers 1422, 1424 form the conventional top cell, overwhich is a window layer 1426, and a cap layer 1428. In anotherembodiment, a complementary structure, with the polarities of one ormore layers switched from those illustrated in FIG. 14A (i.e., P dopedlayers are, instead, N doped, and N doped layers are, instead, P doped),may be used.

As similarly described above, the solar cell is processed, and, asillustrated in FIG. 14B, a back metal contact 1430 and a front metaldiode contact 1440 are formed. In addition, an anti-reflective coating1432 is applied.

In one embodiment, a short integral connector 1436 is formed over aninsulator 1434 from the cap layer 1428 on a small trough 1438 etcheddown through the cell layers 1420-1412 to the tunnel diode layer 1408.An interconnect, such as a C-clamp 1442, may then be used to connect thefront metal contact 1440 and the back metal contact 1430. Thus, thebypass diode 1410 is connected in an anti-parallel configuration withrespect to the photovoltaic portions of the solar cell 1400 and therebyis configured to provide reverse bias protection to the photovoltaicportions of the solar cell 1400.

Using at least some of the techniques described above, a solar cellincorporating an integral diode onto cascaded cells has achievedefficiencies of well over 21%, and even over 23.5%. These efficienciesare comparable to conventional cascade cells lacking the integral bypassdiode. In one embodiment, the integral bypass diode has a forward biasvoltage drop of approximately 1.4 to 1.8 volts when conducting 400 mA offorward current. The reverse breakdown voltage is sufficient to blockcurrent passing into the bypass diode when the solar cell is forwardbiased during normal, unshadowed, illumination. In one embodiment, thereverse breakdown voltage is greater than 2.5V.

Furthermore, samples of one embodiment of the present invention, withcell areas of approximately 24 cm², have sustained repeated 10-secondpulses of 400 mA of reverse current with no significant change inperformance. Thus, for example, when on batch of solar cellsincorporating one embodiment of the integral diode were subjected to2500 pulses of 400 mA reverse current, the following performance changeswere observed:

Pre-test Post-test Parameter Measurement Measurement VOC (OPEN CIRCUITVOLTAGE)  2476 mV  2476 mV ISC (SHORT CIRCUIT CURRENT) 360.5 mA 359.0 mACFF (CURVE FIELD FACTOR) 81.5% 81.5% Efficiency 22.1%   22%

In other testing, when a reverse current greater in magnitude than ISCpassed through the solar cell 100, the area around the diode showed anincrease in temperature of only 10-12° C. This small increase intemperature does not have an appreciable affect, either on theperformance of the photovoltaic portions of the cell, or on the integraldiode.

In another preferred embodiment, the solar cell design described aboveis modified to even further facilitate its use in either space-based orterrestrial-based concentrator systems. Just as in non-concentratorsystems, there is a need to ‘protect against shadowing of the solarcells from clouds, birds, buildings, antennas, or other structures.Thus, protective diodes are still used to protect solar cells fromreverse bias conditions resulting from shadowing. However, solar cellsin concentrator assemblies typically generate much more power thannon-concentrator solar cells. Thus, the protective diodes need to becapable of dissipating heat associated with the much greater power thatis bypassed.

In one embodiment, distributing multiple separated bypass integraldiodes across at least a portion of the surface of the solar cell helpsdistribute the heat dissipation. Thus, each of the multiple integraldiodes bypasses a portion of the reverse bias power, and correspondinglydissipates a portion of the associated heat. Thus, a single integraldiode does not have to bypass all the reverse bias power or dissipateall the heat associated with such bypass function. The multiple integralbypass diodes maybe formed using the same technique described above withregard to forming one integral diode. In one embodiment, differentphotomasks are used to form the diodes and diode contacts.

FIG. 15A illustrates one method of interconnecting in series solar cellshaving integral bypass diodes. By way of example, two solar cells 1502,1510, with corresponding integral bypass diodes 1504, 1514, areinterconnected to form a solar cell string 1500. A first interconnect1508 is connected to a front contact 1506, overlaying cascaded cells ofthe solar cell 1502, and to a front contact 1512, overlaying theintegral bypass diode 1514 of the solar cell 1510, thereby electricallycoupling the solar cells 1502, 1510. The first interconnect 1508 may bea jumper bar, wire, or the like. A second interconnect 1518 is connectedto the front contact 1506 of the solar cell 1502, and to a back contact1516 of the solar cell 1510. The second interconnect 1518 may be az-tab, wire, or the like. In the illustrated embodiment, the bypassdiodes 1504, 1514 are conveniently located on the edge or side oppositethe Ohmic cell contact pads 1506, 1520.

FIG. 15B illustrates another method of interconnecting in series solarcells having integral bypass diodes. As in the previous example, thefirst interconnect 1508 is connected to the front contact 1506 of thesolar cell 1502, and to the front contact 1512 of the solar cell 1510.The second interconnect 1518 is connected to the front contact 1512 andto the back contact 1516 of the solar cell 1510. The second interconnect1518 may be a C-clamp, wire, or the like. This embodiment canadvantageously use only one interconnect between two adjacent cells, andthe series connection between the cells can be made on the frontsurfaces of the cells. Thus, by way of example, the cells can first havetheir corresponding C-clamps individually affixed by the cellmanufacturer. The solar cell panel assembler can then appropriatelyposition the cells in long strings, and then interconnect the frontcontacts of the cells as illustrated in FIG. 15B. This procedure canprovide for the efficient, high yield manufacture of solar cells, solarcell strings, and solar cell panels.

While certain preferred embodiments of the invention have beendescribed, these embodiments have been presented by way of example only,and are not intended to limit the scope of the present invention.

1. A method of manufacturing a solar cell comprising: providing asubstrate; and depositing on the substrate a sequence of layers ofsemiconductor material, including a first region in which the sequenceof layers of semiconductor material forms at least one cell of amultijunction solar cell, and a second region in which the sequence oflayers of semiconductor material forms at least one layer of a bypassdiode to pass current when the solar cell is shaded and to not passcurrent when the solar cell is illuminated; wherein the sequence oflayers in the first region and the sequence of layers in the secondregion are identical, with the same thicknesses and compositions,subject to normal manufacturing variations, and wherein the first regionand the second region are spaced apart.
 2. A method as defined in claim1, further comprising growing the bypass diode over a sequence of layersthat forms at least a portion of one cell of the multijunction solarcell in the first region.
 3. A method as defined in claim 1, furthercomprising depositing a metal layer over the solar cell to interconnecta contact of the multijunction solar cell to a contact of the bypassdiode.
 4. A method as defined in claim 3, wherein the metal layer isdeposited so as to connect a region of a first polarity of the solarcell with a region of a second polarity of the bypass diode.
 5. A methodas defined in claim 1, wherein the sequence of layers includes agermanium substrate.
 6. A method as defined in claim 5, wherein thegermanium substrate includes a photoactive junction.
 7. A method asdefined in claim 3, wherein the metal layer is deposited so as to extendbetween the contact of the bypass diode to a trough that extends throughat least some of the sequence of layers.
 8. A method as defined in claim1, wherein the bypass diode is formed by two layers of the sequence oflayers.
 9. A method as defined in claim 1, further comprising depositingan insulator layer over the sequence of layers.
 10. A method as definedin claim 9, further comprising depositing a metal layer over theinsulator layer for interconnecting at least one layer of themultijunction solar cells with the bypass diode.
 11. A method ofmanufacturing a solar cell comprising: providing a substrate; depositinga sequence of layers of semiconductor material on the substrate to forman integral semiconductor body including a first region in which thesequence of layers of semiconductor material forms at least one cell ofa multijunction solar cell having a contact of first polarity and acontact of second polarity, and a second region in which the sequence oflayers of semiconductor material forms a bypass diode having a contactof a first polarity and a contact of second polarity, the bypass diodefunctioning to pass current when the solar cell is shaded and to notpass current when the solar cell is illuminated; and depositing a metallayer over the multijunction solar cell to interconnect a contact of themultijunction solar cell to a contact of the bypass diode; wherein thesequence of layers in the first region and the sequence of layers in thesecond region are identical, with the same thicknesses and compositions,subject to normal manufacturing variations, and wherein the first regionand the second region are spaced apart.
 12. The method of claim 11wherein the sequence of layers that forms a bypass diode is subsequentlygrown after the growth of a sequence of layers that forms at least aportion of one cell of the multijunction solar cell in the first region.13. The method of claim 11 wherein the metal layer connects a region offirst polarity of the solar cell with a region of a second polarity ofthe bypass diode.